Unit Dose Foam Applicator

ABSTRACT

A unit dose foam applicator according to the present invention comprises an anhydrous, water soluble personal care product for topical use. The product is contained in a pod that is comprised of water soluble film, and the pod is housed in an opened-cell foam pouch. The foam applicator is activated by water. Prior to use, it is preferable if the unit dose foam applicator is disposed in a water-impermeable packette for retail distribution and storage.

FILED OF THE INVENTION

The invention relates to foam pads for the application of awater-soluble product to an application surface, especially for theapplication of topical treatments, such as cosmetic, personal care ormedicinal products to skin, hair or nails.

BACKGROUND

In the personal care industry, foam pads that are formed into a pouchare known. The pouch typically houses a water-soluble cosmetic orpersonal care product. When water is absorbed into and through the foampad, the water soluble product in the pouch dissolves, and diffuses backout through the foam pad until it reaches the outer surface of the pad.From there, the product may be transferred to a surface, such as skin orhair. The transfer is effected by gliding the foam pad over the surfacewith some amount of compression of the pad to squeeze the product out.For example, U.S. Pat. No. 5,762,946 discloses foam pads comprised oftwo sheets of foam of substantially identical size and contours, whichare superposed edge to edge and between which there is encapsulated asolid form of a water-soluble or water-emulsifiable product (such as acosmetic, dermatological or pharmaceutical product), the two sheetsbeing held together by at least one weld along their periphery. Theproducts described in this patent are in the form of a powder, solid gelor cake. Because the foam is open cell or half-open cell, powderproducts have a tendency to leak out through the foam before theintended use. For the same reason, this design is even less suitable forliquid or soft gel products.

Water soluble unit dose packs, sometimes called pods, are also known.These include pouches made from gelatin or from one or more watersoluble films, like polyvinyl alcohol (PVOH). These have been used tocontain a single dose of concentrated detergents and cleaners forindustrial and home use. For example, US2003-148908 discloses ananhydrous detergent encapsulated in a water soluble film based onpolyvinyl alcohol in which it is packaged as a unit dose. The films usedto form pods are typically only a few thousandths of an inch thick,while the product reservoir is large enough to hold one dose of product,for example, 2 mL, 5 mL or 10 mL of product. When dropped into water oraqueous solution, the pod dissolves and releases its contents into thesolution. Such unit dose packs are now common for use in a laundrywashing machine or dishwasher.

OBJECTIVES

A main objective of the invention is to provide a unit dose of a topicalproduct in a single-use, disposable foam applicator. The applicator isactivated by water, and able to distribute the product on an applicationsurface.

SUMMARY

A unit dose foam applicator according to the present invention comprisesan anhydrous, water soluble personal care product for topical use. Theproduct is contained in a pod that is comprised of water soluble film,and the pod is housed in an opened-cell foam pouch. Prior to use, it ispreferable if the foam applicator is disposed in a water-impermeablepackette for retail distribution and storage.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1a depicts a unit dose foam applicator according to the invention.

FIG. 1b is a cut-away of the applicator of FIG. 1a , in which a watersoluble pod can be seen.

FIG. 2a depicts a water soluble pod that houses a single dose of a watersoluble anhydrous product.

FIG. 2b is a cut-away of the water soluble pod of FIG. 2 a.

FIG. 3a depicts a packette in which a unit dose foam applicatoraccording to the invention may be disposed for retail distribution andstorage.

FIG. 3b is a cut-away of the packette of FIG. 3a , in which is disposeda unit dose foam applicator according to the invention.

DETAILED DESCRIPTION

The present invention is described in terms of a personal care orcosmetic product, but other types of products are also contemplated.These include topical medical treatments, such as wound care products.The invention is described in terms of application to a surface of thehuman body (i.e., skin, hair or nails), but other types of surfaces arealso contemplated. These include any surfaces in need of cleansingand/or sterilization.

The term “comprises” means that a recitation of one or more elements maynot be limited to those elements that are explicitly recited.

A unit dose foam applicator (100) according to the present inventioncomprises an opened-cell foam pouch (1), a water soluble pod (2)disposed in the foam pouch, and a water soluble anhydrous product (3)disposed in the water soluble pod. The unit dose foam applicatorpreferably comprises a water-impermeable packette (4).

The Foam Pouch

Referring to FIGS. 1A and 1B, a foam pouch (1) for use in the presentinvention may comprise two sheets of foam (1 c, 1 d) that aresubstantially the same size and shape. When laid one sheet on top of theother, the perimeter of the sheets may be bonded together by anysuitable means, such as high frequency welding, mechanical compression,adhesive or stitching. This creates a reservoir (1 a) inside the pouch,into which one or more water soluble elements may be placed prior tocompleting the perimeter seal. Suitable foams for this purpose includeopen cell foams (i.e. reticulated foams). By “open cell” foam, we mean afoam wherein more than half of the cells are open. The highconcentration of open cells allows fluids to travel through the foampouch, in either direction, which is required by the present invention.Common open cell foam materials include polyurethane, polyvinylchloride, neoprene, polyether, polyester and open cell rubber. Closedcell foams are specifically excluded, because a liquid cannot travelthrough the foam. The size of the cells in the open cell foam maytypically range from 0.5 mm to 5.0 mm, but the invention can bepracticed with even smaller cell sizes. The two sheets of foam can bemade of different materials, different densities, and have differentsurface features, such as flocking and color. As long as the pouchremains dry, the water soluble elements remain encapsulated within thepouch. However, when an exterior surface (1 b) of the pouch is wetted,water is able to flow through the opened cell structure until it reachesthe reservoir (1 a). The water soluble elements within the reservoirbecome wet and begin to dissolve.

The foam applicator can be virtually any shape, but in terms of acircular applicator, and for the applications envisioned, a bath productapplicator may range from about 50 mm to about 150 mm in diameter, andhold a quantity of the product between about 5 ml and about 15 ml. For acleanser or makeup remover for the face, the diameter of the applicatormay be from about 20 mm to about 50 mm, and the quantity of product maybe from about 2 ml to about 10 ml.

The Water Soluble Pod

Water that reaches the reservoir (1 a) of the pouch (1), comes intocontact with the water soluble elements within the pouch. The firstwater soluble element that comes into contact with water is a watersoluble pack or pod (2). A typical water soluble pod is made from awater soluble gelatin or a polyvinyl alcohol (PVOH) film that is only afew thousandths of an inch thick. The water soluble pod may be anyshape, but is preferably the same overall shape as the foam pouch. Theinterior (2 a) of the pod is at least large enough to hold a single doseof a water soluble anhydrous product (3). When water in the reservoir (1a) contacts the pod, the pod begins to dissolve. This exposes the watersoluble product to the water in the reservoir. Preferably, in the courseof a single use of the foam applicator (100), the water soluble podcompletely dissolves.

The Anhydrous Product

The second water soluble element that comes into contact with water inthe reservoir (1 a) is the water soluble anhydrous product (3). Theanhydrous product is sealed in the water soluble pod (2). Once the podbegins to dissolve, the anhydrous product comes into contact with waterin the reservoir, and also begins to dissolve. Before it dissolves, theanhydrous product may be solid or liquid; particulate or gel. The onlylimitations on the type of product are that the product be anhydrous toa degree that does not degrade the water soluble pod before the intendedtime of use by a consumer. Of particular interest are substantiallyanhydrous color cosmetic products, such as foundations and concealers;sun care products such as SPF lotions and after-sun treatments; and skincare products that impart some benefit to the skin. The amount ofproduct sealed in the water soluble pod may range from 1 mL to 20 mL,for example, 1 mL to 10 mL; 1 mL to 5 mL; 2 mL to 15 mL; 2 mL to 10 mL;2 mL to 5 mL, and 5 mL to 15 mL. As the water soluble anhydrous product(3) dissolves, an aqueous solution accumulates in the reservoir (1 a) ofthe pouch (1). Preferably, in the course of a single use of the foamapplicator (100), all of the water soluble anhydrous product dissolves.

The Packette

Optionally, but preferably, each single unit dose foam applicator, asdescribed herein, is disposed in its own packette (4) for retaildistribution and storage. Preferably, the packette is substantiallyimpermeable to water and air. A substantially water-impermeable packettewill ensure that the water soluble pod (2) and water soluble anhydrousproduct (3) do not dissolve before the time of intended use. Thereafterany number of packettes may be packaged for retail sale. For example,the final product can be a set box comprising 10 to 30 packettes.

Alternatively, a number of single unit dose foam applicators (100) canbe packaged into the same water-tight, air-tight bag for retaildistribution. After the bag is opened by a consumer, the length of timethat the pads are exposed to the air may be too short to adverselyaffect the product water soluble pod (2) or the water soluble anhydrousproduct (3).

Method of Use

When a user wants to use the single dose foam applicator according tothe invention, she may tear open a packette, and remove the foamapplicator (100). She then wets the foam pouch (1), and compresses thefoam pouch with her hands to drive the water into the reservoir (1 a) ofthe pouch. As the water soluble anhydrous product (3) dissolves, anaqueous solution accumulates in the reservoir (1 a) of the pouch (1). Asthe foam applicator is further handled and compressed, the aqueoussolution of product diffuses out of the reservoir, through the openedcell structure of the foam, until it reaches an exterior surface (1 b)of the pouch. From there, the solution of product may be transferred toan application surface, such as skin, hair or nails. The transfer iseffected by gliding the foam pouch over the surface with some amount ofcompression of the pouch to prevent the aqueous solution from flowingback into the reservoir. The process may continue until substantiallyall of the aqueous solution has been released from the pouch, andtransferred to an application surface. The foam applicator may be usedto evenly spread the product on the application surface, and to touch upor freshen a previously applied personal care product.

What is claimed is:
 1. A unit dose foam applicator (100) comprising: anopen-cell foam pouch (1), a water soluble pod (2) disposed in the foampouch, and a water soluble anhydrous product (3) disposed in the watersoluble pod.
 2. A unit dose foam applicator (100) according to claim 1,wherein the foam pouch (1) comprises two sheets of foam that are bondedtogether along their perimeter to form a reservoir (1 a) inside the foampouch.
 3. A unit dose foam applicator (100) according to claim 1,wherein the water soluble pod is made of water soluble gelatin orpolyvinyl alcohol.
 4. A unit dose foam applicator (100) according toclaim 1, wherein the amount of product disposed in the water soluble podis in the range of 1 mL to 20 mL.
 5. A unit dose foam applicator (100)according to claim 1, disposed in a packette (4).